U.S. patent application number 16/460904 was filed with the patent office on 2019-10-24 for inkjet printhead with sealed shield plate.
The applicant listed for this patent is Memjet Technology Limited. Invention is credited to David Burke, Nicholas Chin, Elmer Dimaculangan Perez, Mahes Rajaratnam, See-Huat Tan, Jason Thelander, Andrew Thomas, Miao Wang.
Application Number | 20190322103 16/460904 |
Document ID | / |
Family ID | 68237394 |
Filed Date | 2019-10-24 |
United States Patent
Application |
20190322103 |
Kind Code |
A1 |
Perez; Elmer Dimaculangan ;
et al. |
October 24, 2019 |
INKJET PRINTHEAD WITH SEALED SHIELD PLATE
Abstract
An inkjet printhead includes: a support structure having a
plurality of printhead chips mounted thereto; and a shield plate
bonded to the support structure, the shield plate having a slot
aligned with the printhead chips, the slot having a perimeter edge.
A sealant is disposed on all exposed portions of the support
structure adjacent the perimeter edge of each slot.
Inventors: |
Perez; Elmer Dimaculangan;
(North Ryde, AU) ; Chin; Nicholas; (North Ryde,
AU) ; Wang; Miao; (North Ryde, AU) ; Tan;
See-Huat; (North Ryde, AU) ; Thelander; Jason;
(North Ryde, AU) ; Burke; David; (North Ryde,
AU) ; Thomas; Andrew; (North Ryde, AU) ;
Rajaratnam; Mahes; (North Ryde, AU) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Memjet Technology Limited |
Dublin |
|
IE |
|
|
Family ID: |
68237394 |
Appl. No.: |
16/460904 |
Filed: |
July 2, 2019 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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16051319 |
Jul 31, 2018 |
10363736 |
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16460904 |
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15888852 |
Feb 5, 2018 |
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16051319 |
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62455346 |
Feb 6, 2017 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B41J 2002/14419
20130101; B41J 2002/14362 20130101; B41J 2/155 20130101; B41J 2/14
20130101; B41J 2202/08 20130101; B41J 2/1433 20130101 |
International
Class: |
B41J 2/14 20060101
B41J002/14; B41J 2/155 20060101 B41J002/155 |
Claims
1. An inkjet printhead comprising: a support structure having a
plurality of printhead chips mounted thereon; and a shield plate
bonded to the support structure, the shield plate having at least
one slot aligned with one or more printhead chips, the slot having
a perimeter edge, wherein a sealant is disposed on all exposed
portions of the support structure adjacent the perimeter edge of
each slot.
2. The inkjet printhead of claim 1, wherein the sealant has a
profiled surface.
3. The inkjet printhead of claim 1, wherein the sealant tapers
towards the support structure from an upper surface of the shield
plate.
4. The inkjet printhead claim 1, wherein the sealant extends
continuously around an inner perimeter edge of each slot.
5. The inkjet printhead of claim 1, wherein each printhead chip has
a polymer encapsulant extending at least partially along a first
longitudinal edge thereof, the sealant extending between a first
longitudinal edge of each slot and the polymer encapsulant.
6. The inkjet printhead of claim 5, wherein the polymer encapsulant
encapsulates electrical connectors to the printhead chips.
7. The inkjet printhead of claim 5, wherein each printhead chip has
grout material extending at least partially along a second
longitudinal edge thereof, the sealant extending between a second
longitudinal edge of each slot and the grout material.
8. The inkjet printhead of claim 1, wherein the sealant is
comprised of an epoxy polymer.
9. The inkjet printhead of claim 1, wherein the printhead chips are
arranged in one or more rows, each slot being aligned with a
respective row of printhead chips.
10. The inkjet printhead of claim 9, wherein the printhead chips
are arranged in first and second rows, the shield plate have first
and second slots aligned with respective first and second rows of
printhead chips.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a continuation-in-part of U.S.
application Ser. No. 16/051,319 filed Jul. 31, 2018, which is a
continuation-in-part of U.S. application Ser. No. 15/888,852 filed
Feb. 5, 2018, which claims the benefit of priority under 35 U.S.C.
.sctn. 119(e) of U.S. Provisional Application No. 62/455,346, filed
Feb. 6, 2017, the contents of each of which are hereby incorporated
by reference in their entirety for all purposes.
FIELD OF THE INVENTION
[0002] This invention relates to an inkjet printhead. It has been
developed primarily to provide a robust full-color printhead
suitable for high-speed pagewide printing.
BACKGROUND OF THE INVENTION
[0003] The Applicant has developed a range of Memjet.RTM. inkjet
printers as described in, for example, WO2011/143700, WO2011/143699
and WO2009/089567, the contents of which are herein incorporated by
reference. Memjet.RTM. printers employ one or more stationary
inkjet printheads in combination with a feed mechanism which feeds
print media past the printhead in a single pass. Memjet.RTM.
printers therefore provide much higher printing speeds than
conventional scanning inkjet printers.
[0004] Currently, multi-color Memjet.RTM. printheads for desktop
printing are based on a liquid crystal polymer (LCP) manifold
described in U.S. Pat. No. 7,347,534, which delivers four colors of
ink through five color channels (CMYKK) of the printhead to a
plurality of butted printhead chips. The Memjet.RTM. printhead
chips are bonded to a surface of the LCP manifold via an apertured
die-attach film comprised of a central polymer web sandwiched
between opposite adhesive layers. The LCP manifold cooperates with
the die-attach film to direct ink from each of five ink channels to
respective color planes of each printhead chip via a series of
tortuous ink pathways. Redundancy in the black (K) channel is
useful for improving print quality and black optical density.
[0005] However, at high print speeds, the LCP manifold has some
practical limitations. The multiple labyrinthine ink pathways for
delivering multiple inks from the LCP manifold to the printhead
chips may be responsible for unexpected de-priming when the
printhead is running at high speeds. Without a sufficiently large
body of ink close to the printhead chips, the chips may become
starved of ink under periods of high ink demand and lead to chip
de-priming. Secondly, the labyrinthine ink pathways are susceptible
to trapping air bubbles; if an air bubble becomes trapped in the
system, the printhead chips will become starved of ink and
de-prime. It would therefore be desirable to provide a color
printhead suitable for high-speed printing, which is tolerant of
air bubbles and less susceptible to de-prime events.
[0006] Whilst LCP is a satisfactory choice of material for A4
printheads, having a CTE similar to silicon, it typically lacks the
required rigidity to manufacture longer printheads (e.g. A3
printheads). It would be desirable to provide a printhead
architecture suitable for manufacturing printheads that may be
longer than A4-sized.
[0007] Printhead electrical connections in pagewide printheads are
typically via one or more flex PCBs, which wrap around an exterior
sidewall of the printhead. An alternative, more complex approach is
to route electrical wiring through layers of a laminated ceramic
ink manifold (see, for example, U.S. Pat. No. 6,322,206 assigned to
HP, Inc.). However, flex PCBs are expensive and add significantly
to manufacturing costs. Moreover, bending of a flex PCB through a
tight angle places strain on the PCB and limits the components that
may be incorporated thereon. It would therefore be desirable to
provide a robust, inexpensive alternative to conventional
electrical wiring arrangements used in pagewide printheads.
[0008] For inkjet digital presses, multiple monochrome printheads
are typically stacked along a media feed direction, as described in
U.S. Pat. No. 8,845,080. This arrangement enables very high speed
printing by making use of multiple ink channels in each printhead
to print one color of ink. However, a problem with stacking
printheads in this manner is that precise registration of the
printheads is required when printheads are replaced by the user.
Further, there are high demands on media feed mechanisms, which
must maintain alignment of the print media with the printheads
through a relatively long print zone. It would therefore be
desirable to provide a replaceable printhead suitable for desktop
printing, which can print multiple colors at high speeds and does
not require registration of multiple printheads in the field.
SUMMARY OF THE INVENTION
[0009] In a first aspect, there is provided an inkjet printhead
comprising:
[0010] a rigid elongate manifold having first, second, third and
fourth parallel ink supply channels extending along the manifold
and corresponding first, second, third and fourth parallel rows of
outlets defined in the manifold, each row of outlets being in fluid
communication with a respective one of the ink supply channels,
wherein a first ink delivery group contains the first and second
rows of outlets and a second ink delivery group contains the third
and fourth rows of outlets;
[0011] a first array of printhead chips mounted to a unitary lower
surface of the manifold, each first printhead chip receiving ink
from the first and second rows of outlets; and
[0012] a second array of printhead chips mounted to the lower
surface of the manifold, the second array of printhead chips being
parallel and aligned with the array of printhead chips, each second
printhead chip receiving ink from the third and fourth rows of
outlets,
[0013] wherein a distance between the first and second ink delivery
groups is greater than a distance between the first and second rows
of outlets or the third and fourth rows of outlets.
[0014] The printhead according to the first aspect advantageously
enables printing of four colors of ink (e.g. CMYK) from a single
replaceable printhead, whilst simplifying printhead plumbing and
alignment issues. In particular, a multi-channeled printhead chip
may be plumbed for printing two ink colors only and the printhead
chips are attached to a common surface of the manifold in, for
example, two parallel rows to allow printing of all four ink
colors. By arranging two rows of printheads chips on a single
replaceable manifold, the precise alignment of the chips can be
performed with high accuracy at the factory rather than in the
field by a user or technician. Moreover, since each printhead chip
is configured for printing 4 or more (e.g. 4, 5, 6 or 7) ink
channels, then each color has redundancy which increases print
speed and/or minimizes print artifacts caused by dead nozzles. In
the case of a Memjet.RTM. printhead chip having 5 ink channels, the
center channel may be inoperative to provide 2 ink channels for
each color. This arrangement advantageously increases the distance
between color channels printing different colors, thereby
minimizing color mixing on the nozzle plate of the printhead chip.
In other words, the printhead according to the first aspect
provides an excellent compromise between the demands of print
speed, redundancy, printhead alignment and color mixing on the
nozzle plate.
[0015] Preferably, each row of printhead chips is attached to the
lower surface via a respective intervening structure. The
intervening structure is preferably common to a respective row of
printhead chips.
[0016] Preferably, each intervening structure comprises a film or a
shim having a plurality of apertures defined therein.
[0017] Preferably, the shim has a CTE of 5 ppm/.degree. C. or less,
more preferably a CTE of 2 ppm/.degree. C. or less.
[0018] Preferably, the shim is comprised of an alloy of iron and at
least one other metal selected from the group consisting of:
nickel, cobalt and chromium. Typically, the alloy is an Invar
material. Preferably, the Invar material is a single-phase alloy
consisting of around 36% nickel and 64% iron; however, other Invar
variants are within the scope of the present invention.
[0019] Preferably, the shim is received in a respective recessed
portion of the lower surface. The recessed portion may be defined
by one or more step features of the lower surface.
[0020] Preferably, each row of printhead chips comprises a
plurality of butting printhead chips arranged in a line.
[0021] Preferably, each ink supply channel contains a different
colored ink, and each printhead chip is configured for printing two
different colors of ink.
[0022] Preferably, each printhead chip comprises at least two rows
of aligned nozzles for each color of ink. Accordingly, the
printhead has redundancy for each color of ink, which
advantageously improves print quality in a pagewide array.
[0023] Preferably, each printhead chip is asymmetrical about a
longitudinal axis.
[0024] Preferably, the first and second rows of printhead chips
have mirror symmetry, the second row of printhead chips being
oppositely oriented relative to the first row of printhead
chips.
[0025] Preferably, opposite distal longitudinal edges of printhead
chips in the first and second rows have bond pads for electrical
connection to the printhead chips.
[0026] Preferably, a distance between the first and second rows of
printhead chips is less than 50 mm, less than 30 mm, less than 20
mm or less than 15 mm. Preferably, the distance between the first
and second rows of printhead chips is in the range of 5 to 20
mm.
[0027] Preferably, a width of a print zone defined by the first and
second rows of printhead chips is less than 50 mm, less than 30 mm,
less than 20 mm or less than 15 mm. Preferably, the print zone has
a width in the range of 5 to 20 mm.
[0028] In a second aspect, there is provided an inkjet printhead
comprising: [0029] a manifold having a plurality of ink outlets
defined in a manifold surface; [0030] a plurality of printhead
chips mounted to the manifold surface and aligned with the ink
outlets; [0031] a PCB mounted to the manifold surface and offset
from the ink outlets, the PCB being electrically connected to the
printhead chips; and [0032] a shield plate covering the PCB,
wherein the shield plate has one face in thermal contact with the
PCB and an exposed opposite face defining a lower surface of the
printhead.
[0033] The printhead according to the second aspect advantageously
warms a protective shield plate for a printhead so as to minimize
condensation of ink aerosol on the shield plate during printing.
Condensation of ink aerosol is problematic in inkjet printers,
especially during longer print runs, because formation of condensed
ink droplets on the printhead potentially result in a reduction in
print quality.
[0034] Preferably, the shield plate is electrically insulating.
[0035] Preferably, the printhead chips are mounted to the manifold
surface via a shim.
[0036] Preferably, the shield plate intimately contacts a lower
surface of the PCB.
[0037] Preferably, the PCB is a rigid PCB (e.g. a PCB based on
FR4)
[0038] Preferably, the lower surface of the PCB is coplanar with a
lower surface of the shim.
[0039] Preferably, the PCB is thicker than the shim and the
manifold surface is stepped to accommodate the PCB and the shim
having respective coplanar lower surfaces.
[0040] Preferably, the shield plate is bonded to the PCB and part
of the shim.
[0041] Preferably, the shim has at least one void region offset
from the printhead chips, the void region thermally isolating part
of the shield plate from the manifold.
[0042] Preferably, the printhead comprises a row of printhead chips
and the PCB extends longitudinally adjacent the row of printhead
chips.
[0043] Preferably, the printhead comprises first and second rows of
printhead chips, the first row of printhead chips having a
respective first PCB and the second row of printhead chips having a
respective second PCB, wherein the first and second PCBs are
positioned at opposite distal longitudinal sides of the first and
second rows of printhead chips.
[0044] Preferably, the first and second PCBs wrap at least
partially around ends of the first and second rows of printhead
chips.
[0045] Preferably, a central longitudinal region is defined between
the first and second rows of printhead chips.
[0046] Preferably, the shield plate is a perimeter shield plate
covering the first and second PCBs, the perimeter shield plate
having a central leg covering the central longitudinal region.
[0047] Preferably, the first and second rows of printhead chips are
mounted to the manifold via a shim, wherein the shim has at least
one void region coincident with the central longitudinal region,
the void region thermally isolating the central leg of the shield
plate from the manifold.
[0048] In a third aspect, there is provided an inkjet printhead
comprising:
[0049] a rigid elongate manifold having one or more ink supply
channels extending along its length and a plurality of ink outlets
defined therein;
[0050] a shim attached to the manifold, the shim having a plurality
of shim apertures for receiving ink from the ink outlets; and
[0051] a plurality of printhead chips adhesively bonded to the
shim, each printhead chip receiving ink from one or more of the ink
outlets;
[0052] wherein: [0053] the shim is comprised of a metal alloy
having a coefficient of thermal expansion (CTE) of 5 ppm/.degree.
C. or less; and [0054] the metal alloy is coated with an
adhesion-promoting layer.
[0055] The invention according to the third aspect advantageously
enables the construction of relatively long monolithic printheads,
which may be longer than A4-sized (e.g. greater than 210 mm in
length). For example, the invention according to the second aspect
enables the construction of monolithic A3-sized printheads.
[0056] As foreshadowed above, LCP is a common choice of material
for pagewide printheads due to its moldability, stiffness and
relatively low CTE. However, whilst stiffer than other plastics,
LCP does not have the requisite rigidity for the construction of
long monolithic printhead manifolds. Although metals are an obvious
choice of material for constructing rigid printhead manifolds, the
thermal expansion properties of metals are not generally considered
to be suitable for attachment of printhead chips directly onto the
metal due to the mismatch in thermal expansion characteristics
between the metal and silicon. One approach to the problem of
constructing longer printheads is to thermally isolate each
printhead chip on its own respective carrier. However, individual
printhead chip carriers are unsuitable for a rows of butting
printhead chips and increase a width of the print zone.
[0057] The printhead according to the third aspect employs a
suitable metal alloy (e.g. Invar) shim for adhesive bonding of a
plurality of printhead chips to the manifold using, for example, an
epoxy adhesive applied as a liquid to one or both bonding surfaces.
The shim has minimal expansion at high temperatures and provides a
stable structure for mounting a plurality of printhead chips to the
manifold. This, in turn, provides greater flexibility in the choice
of materials for the manifold. The manifold may be comprised of a
material which is the same or different than the shim, and may be
selected on the basis of stiffness, cost, manufacturability etc.
For example, the manifold may be comprised of a material, such as
stainless steel, Invar or a polymer. Typically, the manifold is
comprised of a same material as the shim.
[0058] The adhesion-promoting surface film layer may be comprised
of a coating material selected from the group consisting of:
diamond-like carbon (DLC), metal oxide (e.g. alumina, silica,
tantala, hafnia etc.), metal nitride (e.g. silicon nitride,
chromium nitride etc.), metal (e.g. chromium, stainless steel etc.)
and a polymer. The adhesion-promoting surface film layer assists in
bonding the printhead chips to the shim with via an adhesive to
provide a robust printhead structure. Likewise, shim-to-manifold
bonding strength may be improved via the adhesion-promoting surface
film layer
[0059] The surface film layer may be comprised of a monolayer
coating or a multilayer coating and may have a thickness in the
range of 50 nm to 5 microns.
[0060] Typically, the surface film layer is deposited or formed on
the metal alloy via a process selected from the group consisting
of: chemical vapor deposition (CVD), plasma-enhanced chemical vapor
deposition (PECVD), physical vapor deposition (PVD), atomic layer
deposition (ALD), metallization and nitriding.
[0061] Specific examples of the surface film layer include: single
layer DLC PECVD, multilayer DLC PECVD, single layer DLC PVD, hybrid
multilayer DLC PVD-PECVD, alumina ALD, tantala ALD, nitriding
surface treatment, chromium metallization, stainless steel
metallization, single layer chromium nitride plasma coating, and
multilayer chromium nitride plasma coating.
[0062] In a further aspect, there is provided a shim for attachment
of one or printhead chips to a printhead manifold, the shim having
a plurality of ink supply openings defined therein, wherein the
shim is comprised of a metal alloy having a coefficient of thermal
expansion (CTE) of 5 ppm/.degree. C. or less and the metal alloy
includes an adhesion-promoting surface film layer as defined above.
Typically, the shim has a thickness in the range of 100 to 1000
microns.
[0063] Preferably, the shim is comprised of an alloy of iron and at
least one other metal selected from the group consisting of:
nickel, cobalt and chromium.
[0064] Preferably, the manifold is a one-piece structure.
[0065] Preferably, the manifold has a longitudinal ink cavity
defined in a lower surface thereof, and wherein the shim is
attached to a lower surface of the manifold so as to bridge across
the longitudinal ink cavity.
[0066] Preferably, the longitudinal ink cavity has a roof and
sidewalls extending between the roof and the lower surface, the
plurality of ink outlets being defined in the roof
[0067] Preferably, a longitudinal rib divides the ink cavity into
longitudinal ink feed channels at either side of the rib, the rib
having a lower surface coplanar with the lower surface of the
manifold.
[0068] Preferably, the shim is bonded to the lower surfaces of the
rib and the manifold.
[0069] Preferably, each printhead chip has a central portion
aligned with the rib and opposite side portions overlapping with
respective longitudinal ink feed channels.
[0070] Preferably, the shim and a PCB are adjacently bonded to a
lower surface of the manifold.
[0071] Preferably, the shim and the PCB have coplanar lower
surfaces.
[0072] Preferably, the lower surface of the manifold is stepped to
accommodate different thicknesses of the shim and the PCB.
[0073] In a fourth aspect, there is provided an inkjet printhead
comprising:
[0074] a rigid elongate manifold having at least one ink supply
channel and a lower surface with a longitudinal ink cavity defined
therein, the longitudinal ink cavity having a roof and sidewalls
extending between the roof and the lower surface;
[0075] a shim attached to the lower surface so as to bridge across
the longitudinal ink cavity, the shim having a plurality of shim
apertures for receiving ink from the longitudinal ink cavity; and a
plurality of printhead chips attached to the shim, each printhead
chip receiving ink from the longitudinal ink cavity via one or more
of the shim apertures, wherein a plurality of through-holes are
defined in the manifold to provide fluid communication between the
ink supply channel and the longitudinal ink cavity, each
through-hole having a first portion with a first end defined in the
roof and a second portion extending through a respective sidewall
with a second end defined in the lower surface of the manifold, the
shim sealing the second end.
[0076] The printhead according to the fourth aspect advantageously
provides an open back channel architecture for the printhead chips,
which facilitates escape of any bubbles emanating from the chips
and/or escape of bubbles otherwise trapped in the printhead. In
particular, the second portions of the through-holes maximize the
opportunity for venting of bubbles into relatively large ink supply
channels where the bubbles can be easily flushed from the
printhead. Furthermore, the longitudinal ink cavity having a
bridging shim avoids labyrinthine ink pathways in the printhead,
thereby maximizing the availability of ink to the printhead chips
and minimizing the risk of inkjet nozzles becoming starved of ink
at high print frequencies.
[0077] Preferably, at least part of the second portion of each
through-hole is offset from a respective printhead chip.
[0078] Preferably, each second portion is configured to enable an
air bubble to rise from a respective printhead chip towards the ink
supply channel.
[0079] Preferably, each second portion defines a notch in a
respective sidewall.
[0080] Preferably, each through-hole is circular and the first and
second portions are generally semi-circular.
[0081] In a fifth aspect, there is provided an inkjet printhead
comprising: [0082] a rigid elongate manifold having at least one
ink supply channel and a lower surface having a plurality of
printhead chips mounted thereon;
[0083] a rigid PCB attached to the lower surface of the manifold,
the PCB extending a length of the manifold and projecting laterally
beyond a sidewall of the manifold;
[0084] a lead retainer attached to the sidewall of the manifold;
and
[0085] a plurality of leads extending upwardly from contact pads
positioned along a first longitudinal edge portion of the PCB, each
lead being secured to the sidewall of the manifold via the lead
retainer, wherein the PCB supplies power and data to the printhead
chips via electrical connections between the PCB and the printhead
chips.
[0086] The printhead according to the fifth aspect advantageously
provides a robust wiring arrangement for supplying power and data
to printhead chips via a conventional PCB based on, for example, an
FR-4 substrate.
[0087] Preferably, the printhead comprises a pair of PCBs flanking
a pair of rows of printhead chips, each PCB supplying power and
data to a respective row of printhead chips.
[0088] Preferably, each PCB is covered by a shield plate
surrounding the printhead chips, the shield plate defining a
capping surface for the printhead.
[0089] Preferably, the printhead is symmetrical about a central
longitudinal plane.
[0090] Preferably, the lower surface of the manifold has a step and
an opposite second longitudinal edge portion of the PCB is butted
against the step.
[0091] Preferably, the leads are flared outwardly from the lead
retainer towards the contact pads of the PCB.
[0092] In a sixth aspect, there is provided an inkjet printhead
comprising:
[0093] a rigid elongate manifold having one or more ink supply
channels extending along its length, each ink supply channel having
a base defining a plurality of ink outlets and a roof comprising an
elongate flexible film; and a plurality of printhead chips mounted
to the manifold, each printhead chip receiving ink from one or more
of the ink outlets, wherein the flexible film comprises a plurality
of operatively independent bellows positioned along a length of the
flexible film.
[0094] The printhead according to the sixth aspect advantageously
provides dynamic responses to pressure changes in elongate ink
supply channels. In particular, the plurality of discrete bellows
enables a rapid, dynamic response to localized pressure changes in
any given region of an ink supply channel, whilst avoiding
undesirable resonance effects in other regions of the ink supply
channel. Moreover, the printhead according to the sixth aspect
enables dampening of pressure spikes in degassed inks, in contrast
with printheads having air boxes for dampening pressure spikes.
[0095] Preferably, each bellows comprises a corrugated region of
the flexible film.
[0096] Preferably, the bellows are operatively separated from each
other by baffles.
[0097] Preferably, the baffles extend upwards from a continuous
corrugated film so as to divide the film into contiguous and
operatively independent bellows.
[0098] Preferably, the printhead comprises a cover plate engaged
with the manifold and positioned for covering the flexible film,
the cover plate having a plurality of vent holes open to
atmosphere.
[0099] Preferably, wherein the flexible film is comprised of a
polymer.
[0100] Preferably, each ink supply channel has a manifold port at
one longitudinal end and the bellows hang into the ink supply
channel from sidewalls thereof.
[0101] Preferably, a level of the manifold port corresponds to a
level of a lowest part of the bellows hanging into the ink supply
channel.
[0102] In a seventh aspect, there is provided a multi-channel fluid
coupling for a printhead, the fluid coupling comprising: [0103] a
body having a first channel and a second channel, the second
channel being relatively longer than the first channel; [0104] a
first inlet port and a first outlet port at opposite ends of the
first channel; and [0105] a second inlet port and a second outlet
port at opposite ends of the second channel, wherein:
[0106] the first and second channels are configured for
proportionally modulating a flow resistance of fluids flowing
therethrough.
[0107] The fluid coupling of the seventh aspect advantageously
compensates for pressure drops due to different length fluid
channels in the fluid coupling. Thus, relatively longer and
relatively shorter fluid channels in the coupling will have the
same or similar pressure drops. Typically, longer channels
experience greater pressure drops than similarly dimensioned
shorter channels due to increased viscous drag. This is undesirable
in systems, such as printhead ink delivery systems, where ink
pressures are critical for optimizing printhead performance and,
ultimately, print quality. The fluid coupling of the seventh aspect
allows compact fluid couplings to be designed with relatively
longer and relatively shorter channels, whilst at the same time
minimizing pressure drop differences for fluids exiting the fluid
coupling. In this way, pressure regulators upstream of the fluid
coupling can set relative fluid pressures for an inkjet printhead
without being undermined by idiosyncratic fluid dynamics of the
fluid coupling.
[0108] Preferably, the flow resistance of the fluids flowing
through the first and second channels are equalized.
[0109] Preferably, the second channel comprises at least a portion
having a larger cross-sectional area than the first channel.
[0110] Preferably, the second channel has a sloped wall.
[0111] Preferably, the first and second outlet ports extend
transversely relative to the first and second inlets ports.
[0112] Preferably, the second channel has a roof sloped from the
outlet channel towards the inlet channel.
[0113] Preferably, a plurality of first channels and a plurality of
second channels.
[0114] Preferably, the first inlet ports being relatively proximal
the first outlet ports and the second inlet ports being relatively
distal the second outlet ports.
[0115] Preferably, the fluid coupling comprises two first channels
and two second channels for four ink colors.
[0116] Preferably, the inlet ports or the outlet ports are arranged
radially.
[0117] In a further aspect, there is provided an inkjet printhead
comprising: [0118] a manifold having at least first and second ink
supply channels; and [0119] a fluid coupling as described above
connected to at least one end of the manifold.
[0120] The fluid coupling may be the fluid coupling may be an inlet
coupling for the printhead. Preferably, the inlet ports of the
inlet coupling extend perpendicularly relative to a longitudinal
axis of the printhead.
[0121] Preferably, the inlet ports extend in an opposite direction
to an ink ejection direction of the printhead.
[0122] Preferably, the first and second ink supply channels extend
longitudinally along the manifold.
[0123] In an eighth aspect, there is provided an inkjet printhead
comprising: [0124] a manifold having a plurality of ink outlets
defined in a manifold surface; [0125] a shim adhesively bonded to
the manifold surface, the shim having apertures aligned with the
ink outlets; [0126] a first row of printhead chips adhesively
bonded to the shim; and [0127] a second row of printhead chips
adhesively bonded to the shim, wherein the shim is a one-part
common shim for mounting all printhead chips of the first and
second row.
[0128] The printhead according to the eighth aspect advantageously
facilitates relative alignment of multiple rows of printhead
chips.
[0129] Preferably, the shim comprises first and second longitudinal
shim portions corresponding to the first and second rows of
printhead chips, each of the first and second longitudinal shim
portions comprising respective first and second apertures.
[0130] Preferably, the first and second longitudinal shim portions
are interconnected via a plurality of trusses. Typically, the
trusses extend transversely relative to the longitudinal shim
portions.
[0131] Preferably, the shim is comprised of a metal or metal alloy.
Typically, the shim and the manifold are comprised of a same
material.
[0132] Preferably, the shim comprises a plurality of mechanical
alignment tabs engaged with complementary alignment features
defined in the manifold surface.
[0133] Preferably, the shim comprises first and second longitudinal
shim portions interconnected via a plurality of trusses and wherein
the trusses comprise one or more of the alignment tabs.
[0134] Preferably, the first and second rows comprise a plurality
of printheads chips butted together in a line.
[0135] In a ninth aspect, there is provided a printhead cartridge
comprising: [0136] an elongate manifold; [0137] a plurality of
printhead chips mounted to a lower part of the manifold; and [0138]
a casing mounted to an upper part of the manifold, wherein the
casing comprises a first casing part and a second casing part, the
first and second parts being longitudinally biased towards each
such that the casing is expandable along a longitudinal axis of the
manifold.
[0139] The printhead cartridge according to the ninth aspect
advantageously minimizes strain in the manifold caused by
longitudinal expansion during use. Typically, printhead cartridges
have a casing for user handling, which is attached to the manifold.
In relatively short printheads, any longitudinal expansion of the
manifold is relatively small; however, in longer printheads (e.g.
A3-sized printheads) thermal expansion of the manifold becomes more
significant and a rigid casing unduly constraining longitudinal
expansion will result in bowing of the printhead and a loss of
print quality. The two-part casing according to the ninth aspect
minimizes bowing, especially in longer printheads.
[0140] Preferably, the casing is configured for user handling of
the printhead cartridge.
[0141] Preferably, the printhead cartridge comprises a central
locator positioned between the first and second casing parts.
[0142] Preferably, the first and second casing parts are biased
towards the central locator.
[0143] Preferably, the first and second casing parts are
interconnected via a spring clip bridging across the central
locator.
[0144] Preferably, the central locator has an alignment feature for
aligning the printhead cartridge during user insertion in a
printer.
[0145] Preferably, the manifold is comprised of a metal or metal
alloy and may be a one-piece structure.
[0146] Preferably, the manifold is comprised of a metal alloy
having a CTE of of 5 ppm/.degree. C. or less.
[0147] Preferably, the the casing has openings at one or both ends
thereof for receiving ink connectors. The ink connectors may be
connected to a fluid coupling of the type described above.
[0148] In a tenth aspect, there is provided an inkjet printhead
comprising: [0149] a manifold having a plurality of ink outlets
defined in a manifold surface; [0150] a plurality of printhead
chips mounted to the manifold surface, each printhead chip having
an odd number of color channels, each color channel having at least
one respective row of inkjet nozzle devices, wherein a central
color channel of each printhead chip is a dummy color channel that
does not receive ink from the manifold.
[0151] The printhead according to the tenth aspect advantageously
employs a dummy color channel to improve structural integrity of
the printhead as well as, in some embodiments, provide improved
thermal regulation during use. Moreover, printheads having, for
example, five color channels may be adapted for printing two colors
with redundancy in each color whilst enjoying the aforementioned
advantages of improved robustness and, optionally, thermal
regulation.
[0152] Preferably, the dummy color channel is absent an ink supply
channel defined in a backside surface of the printhead.
[0153] Preferably, a longitudinal rib of the manifold surface is
aligned with the dummy color channel.
[0154] Preferably, the printhead chips are mounted to the manifold
surface via a shim.
[0155] Preferably, the shim has a shim rib aligned with the
longitudinal rib of the manifold surface and a pair of longitudinal
shim slots at either side of the shim rib for receiving ink from
respective ink outlets of the manifold.
[0156] Preferably, only color channels at either side of the dummy
color channel receive ink from the manifold.
[0157] Preferably, each printhead chip receives two different
colors of ink from the manifold.
[0158] Preferably, a pair of longitudinal ink feed channels are
defined at either side of the longitudinal rib, each longitudinal
ink feed channel delivering ink to at least one respective color
channel, or more preferably, a plurality of respective color
channels.
[0159] In one embodiment, each printhead chip comprises five color
channels including a central dummy channel, wherein a first pair of
color channels at one side of the dummy color channel print a first
ink and a second pair of color channels at an opposite side of the
dummy color channel print a second ink.
[0160] Preferably, each color channel comprises a pair of rows of
inkjet nozzle devices.
[0161] In some embodiments, inkjet nozzles devices of the dummy
color channel are electrically to a PCB.
[0162] Preferably, the inkjet nozzle devices are thermally-actuated
devices, such that, in use, the dummy color channel facilitates
temperature regulation of a respective printhead chip via actuation
of the inkjet devices in the dummy color channel.
[0163] In a further aspect, there is provided a printhead chip
having an odd number of color channels, each color channel
comprising at least one row of inkjet nozzle devices, wherein a
central color channel of the printhead chip is a dummy color
channel that does not receive any ink.
[0164] Inkjet nozzle devices of the dummy color channel may be
electrically connected to drive electronics in the printhead chip
for thermal regulation.
[0165] It will be appreciated that preferred embodiments as
described above in connection with certain aspects of the invention
may be equally applicable to each of the first, second, third,
fourth, fifth, sixth, seventh, eighth, ninth and tenth aspects.
Preferred embodiments described above are not intended to be
strictly associated with one particular aspect and the skilled
person will readily appreciate where preferred embodiments are
applicable to certain other aspects of the invention.
[0166] As used herein, the term "ink" is taken to mean any printing
fluid, which may be printed from an inkjet printhead. The ink may
or may not contain a colorant. Accordingly, the term "ink" may
include conventional dye-based or pigment-based inks, infrared
inks, fixatives (e.g. pre-coats and finishers), 3D printing fluids
and the like. Where reference is made to fluids or printing fluids,
this is not intended to limit the meaning of "ink" herein.
[0167] As used herein, the term "mounted" includes both direct
mounting and indirect mounting via an intervening part.
BRIEF DESCRIPTION OF THE DRAWINGS
[0168] Embodiments of the present invention will now be described
by way of example only with reference to the accompanying drawings,
in which:
[0169] FIG. 1 is a front perspective view of an inkjet
printhead;
[0170] FIG. 2 is a bottom perspective of the printhead;
[0171] FIG. 3 is an exploded perspective of the printhead;
[0172] FIG. 4 is a magnified view of a central portion of a casing
of the printhead;
[0173] FIG. 5 is an exploded perspective of a main body of the
printhead with inlet and outlet couplings;
[0174] FIG. 6 is a perspective of a fluid coupling;
[0175] FIG. 7A is a sectional perspective through a first channel
of the fluid coupling;
[0176] FIG. 7B is a sectional perspective through a second channel
of the fluid coupling;
[0177] FIG. 8 is a magnified exploded perspective of an end of the
main body with one fluid coupling removed;
[0178] FIG. 9 is a magnified top perspective of an ink manifold
with a flexible film removed;
[0179] FIG. 10 is a sectional perspective of the ink manifold;
[0180] FIG. 11 is a magnified cross-sectional perspective of the
ink manifold with a shim and one row of printhead chips
removed;
[0181] FIG. 12 is a magnified bottom perspective of a lower surface
of the ink manifold;
[0182] FIG. 13 is a sectional side view of a shim and printhead
chip mounting arrangement;
[0183] FIG. 14 is a sectional bottom perspective of the shim and
printhead chip mounting arrangement;
[0184] FIG. 15 shows an individual printhead chip;
[0185] FIG. 16 is a top perspective of part of the shim;
[0186] FIG. 17 is a sectional side perspective of the
printhead;
[0187] FIG. 18 is a bottom perspective of part of the
printhead;
[0188] FIG. 19 is a magnified bottom perspective of the printhead
with a shield plate and one row of encapsulant removed;
[0189] FIG. 20 is a schematic sectional side view of the printhead
with perimeter sealant around slots in the shield plate.
DETAILED DESCRIPTION OF THE INVENTION
[0190] Referring to FIGS. 1 to 4, there is shown an inkjet
printhead 1 in the form of a replaceable printhead cartridge for
user insertion in a printer (not shown). The printhead 1 comprises
an elongate molded plastics casing 3 having a first casing part 3A
and a second casing part 3B positioned at either side of a central
locator 4. The central locator 4 has an alignment notch 5 for
positioning the printhead cartridge 1 relative to a print module,
such as a print module of the type described in US2017/0313061, the
contents of which are incorporated herein by reference. The first
and second casing parts 3A and 3B are biased towards each other and
the central locator 4 by means of a spring clip 6 engaged between
the first and second casing parts (see FIG. 4). The two-part casing
3 in combination with the spring clip 6 enables the casing to
expand longitudinally, at least to some extent, to accommodate a
degree of longitudinal expansion in a main body 17 of the printhead
1. This arrangement minimizes stress or bowing of the main body 17
of the printhead 1 during use.
[0191] Inlet connectors 7A of a multi-channel inlet coupling 8A
protrude upwards through openings at one end of the casing 3; and
outlet connectors 7B of a multichannel outlet coupling 8B protrude
upwards through opening at an opposite end of the casing (only two
inlet connectors and two outlet connectors shown in FIG. 1). The
inlet and outlet connectors 7A and 7B are configured for coupling
with complementary fluid couplings (not shown) supplying ink to and
from the printhead. The complementary fluid couplings may be, for
example, part of an ink delivery module and/or print module of the
type described in US2017/0313061.
[0192] The printhead 1 receives power and data signals via opposite
rows of electrical contacts 13, which extend along respective
sidewalls of the printhead. The electrical contacts 13 are
configured to receive power and data signals from complementary
contacts of a printer (not shown) or print module and deliver the
power and data to printhead chips 70 via a PCB, as will be
explained in more detail below.
[0193] As shown in FIG. 2, the printhead 1 comprises a first row 14
and a second row 16 of printhead chips for printing onto print
media (not shown) passing beneath the printhead. Each row of
printhead chips is configured for printing two colors of ink, such
that the printhead 1 is a full color pagewide printhead capable of
printing four ink colors (CMYK). The printhead 1 is generally
symmetrical about a longitudinal plane bisecting the first row 14
and the second row 16 of printhead chips, notwithstanding the
different ink colors in the printhead during use.
[0194] In the exploded perspective shown in FIG. 3, it can be seen
that the main body 17 forms a rigid core of the printhead 1 for
mounting various other components. In particular, the casing 3 is
snap-fitted to an upper part of the main body 17; the inlet and
outlet couplings 8A and 8B (enshrouded by the casing 3) are
connected to opposite ends of the main body; a pair of PCBs 18 are
attached to a lower part of the main body (which are in turn
covered by a shield plate 20); and a plurality of leads 22 (which
define the electrical contacts 13) are mounted to opposite
sidewalls of the main body.
[0195] Referring to FIG. 5, the main body 17 is itself a two-part
machined structure comprising an elongate manifold 25 and a
complementary cover plate 27. The manifold 25 functions as a
carrier having a unitary lower surface for mounting both the first
and second rows 14 and 16 of printhead chips. The manifold 25 is
received between a pair of opposed flanges 29, which extend
downwardly from opposite longitudinal sides of the cover plate 27.
The flanges 29 are configured for snap-locking engagement with
complementary snap-locking features 26 of the manifold 25 to form
the assembled main body 17.
[0196] The manifold 25 and cover plate 27 are formed of a metal
alloy material having excellent stiffness and a relatively low
coefficient of thermal expansion (e.g. Invar). In combination, the
manifold 25 and cover plate 27 provide a stiff, rigid structure at
the core of the printhead 1 with minimal expansion along its
longitudinal axis. As foreshadowed above, the casing 3 is
configured so as not to constrain any longitudinal expansion of the
main body 17 and thereby minimizes bowing of the printhead during
use. Accordingly, the printhead 1 may be provided as an A4-length
printhead or an A3-length printhead. It is an advantage of the
present invention that a single pagewide printhead may be
configured up to A3-length (i.e. up to 300 mm). Hitherto, pagewide
printing onto A3-sized media was only possible via multiple
printhead modules stitched together in a pagewide array and the
printhead 1, therefore, expands the commercial viability for
A3-sized, color pagewide printing.
[0197] FIG. 6 shows in detail one of the multi-channel fluid
couplings 8, which may be either the inlet coupling 8A or the
outlet coupling 8B. However, for the purposes of describing
features in connection with FIG. 6, the fluid coupling 8 shown is
assumed to be the inlet coupling 8A.
[0198] The fluid coupling 8 is designed to transfer four colors of
ink through a 90-degree angle for vertical coupling of the
printhead 1 to, for example, a complementary fluid coupling of a
print module, whilst ensuring that four fluid connectors can be
geometrically accommodated within the space constraints of the
printhead and its surrounds. Furthermore, the fluid coupling 8 is
designed to equalize any pressure drops through the fluid coupling,
such that the four ink colors have the same or similar relative
pressures when they enters the manifold 25.
[0199] Referring then to FIGS. 6, 7A and 7B, the fluid coupling 8
comprises four inlet ports 9A-D, which extend vertically upwards
from a coupling body 10, and corresponding outlet ports 11A-D
extending from the coupling body perpendicular to the inlet ports.
The inlet ports 9A-9D are radially arranged about the coupling body
10, such that the two outer inlet ports 9A and 9D are relatively
proximal their respective outlet ports 11A and 11D; and the two
inner inlet ports 9B and 9C are relatively distal their respective
outlet ports. The radial arrangement of the inlet ports 9A-9D
enables the inlet ports to be accommodated within the space
constraints of a print module (not shown) engaged with the
printhead. Furthermore, the inlet ports have coplanar upper
surfaces for simultaneous vertical engagement/disengagement during
printhead insertion/removal.
[0200] Each ink entering the fluid coupling 8 has a carefully
controlled respective hydrostatic pressure (e.g. by virtue of an
upstream pressure regulator) and it is important that the relative
hydrostatic pressures of the inks are not changed as the inks flow
through the fluid coupling. For example, the four inks may enter
the inlets ports 9A-9D with equal hydrostatic pressures and it is
desirable that these inks exit the outlet ports 11A-11D into the
manifold 25 with equal hydrostatic pressures. A degree of pressure
drop is, to some extent, inevitable as each ink experiences flow
resistance (i.e. viscous drag) through the fluid coupling 8;
however, it is important that the pressure drops are equalized for
all inks despite the longer fluidic paths for the two inks flowing
through the two inner inlet ports 9B and 9C. Accordingly, as shown
in FIG. 7B, a fluid channel 12B connecting the inlet port 9B with
the outlet port 11B has a roof 13B sloped upwards from towards the
inlet port 9B. A roof 13C of a corresponding fluidic channel
connecting the inlet port 9C and the outlet port 11C is, likewise,
sloped upwards towards the inlet port 9C. By contrast the fluid
channel 12A connecting inlet port 9A with the outlet port 11A does
not have a similarly sloped roof, requiring the fluid to turn
through a tighter angle without assistance from a more curved fluid
path.
[0201] Thus, the roof configuration of the two inner fluid channels
12B and 12C has the effect of negating any additional flow
resistance that might be caused by their relatively longer fluidic
paths compared to the two outer fluid channels 12A and 12D. Thus, a
pressure drop through the fluid coupling 8 is the same or similar
for all four fluid channels 12A-12D and each of the four outlet
ports 11A-11D will have equal hydrostatic pressures when inks
entering the four inlet ports 9A-D have equal hydrostatic
pressures. By contrast, fluid connectors for printheads known in
the art, such as the fluid connector described in U.S. Pat. No.
7,399,069 (assigned to HP, Inc.), have appreciable differences in
flow resistances (and pressure drops) for various fluid channels
with different lengths.
[0202] FIG. 8 is a magnified view of an outlet end of the manifold
25 and cover plate 27 together with the outlet coupling 8B. It will
be seen that the cover plate 27 has a plurality of vent holes 30
spaced apart along its length, which are open to atmosphere so as
to allow free flexing of a flexible film 31 attached to an upper
part of the manifold 25. The function of the flexible film 31 will
be described in further detail below.
[0203] Still referring to FIG. 8, the multi-channel outlet coupling
8B receives ink from manifold ports 34 at one end of the manifold
25. Likewise, the multi-channel inlet coupling 8A delivers ink to
manifolds ports 34 at an opposite end of the manifold 25. Of
course, alternative coupling arrangements are within the ambit of
the present invention.
[0204] Referring now to FIGS. 9 and 10, the ink manifold 25
comprises four ink supply channels 40 extending longitudinally and
parallel with manifold sidewalls 41. Each ink supply channel 40 is
supplied with ink from a manifold port 34 at one end of the
manifold 25 and ink exits the ink supply channel via a manifold
outlet 34 at an opposite end of the manifold. The ink supply
channels 40 are capped by the flexible film 31, covering an upper
part of the manifold 25, with the flexible film 31 including a
plurality of discrete corrugated sections or bellows 43.
[0205] Typically, printing systems are developed with several
subsystems having differing fluidic response frequencies and the
bellows 43 are designed to respond rapidly to hydrostatic pressure
changes in the printhead 1. In order to maintain optimum ejection
performance, internal pressures within the printhead 1 should
optimally be maintained within a relatively narrow pressure window
so as to allow nozzle refill consistency. Since ink delivery
systems, which supply ink to the printhead 1, typically have a
relatively slow response to dynamic pressure changes, rapid refill
of inkjet nozzles in the printhead is controlled locally by the
bellows 43 taking up an ejected volume of ink until the ink
delivery system can respond. Similarly, the bellows 43 also perform
a dampening function and can "absorb" pressure spikes when printing
at full ink flow stops suddenly.
[0206] It will be appreciated that the number and configuration of
bellows 43 may be modified to optimize the performance of the
printhead 1. In particular, the number and configuration of bellows
43 may be optimized to minimize undesirable resonance effects along
the length of the ink supply channel 40. In this way, high ink
demand in one portion of the ink supply channel 40 can be met by a
number of bellows 43, without inducing a standing wave across an
entire length of the flexible film 31. The bellows 43 may be
separated into discretely operating units either by being spaced
apart along the length of the film (e.g. with intervening planar
sections of the film), or, as shown in FIGS. 9 to 11, by dividing
the flexible film 31 into longitudinal sections using transverse
baffles 45. The baffles 45 minimize generation of standing waves
along a whole length of the film 31, whilst enabling the film to be
molded from a single piece covering all four ink supply channels,
thereby facilitating fabrication of the printhead 1.
[0207] It will be further appreciated that the bellows 43 can
respond to pressure fluctuations without requiring air boxes, such
as those described in U.S. Pat. No. 8,025,383. Therefore, the
printhead 1 is suitable for use with degassed inks.
[0208] As best seen in FIG. 10, the bellows 43 `hang` from an upper
surface of the manifold 25 into each of the ink supply channels 40.
The bellows 43 hang down to a level corresponding to a level of the
manifold ports 34, such that any air bubbles cannot become trapped
in a headspace of the ink supply channels 40 below the bellows.
Thus, if undesired air bubbles enter the ink supply channels 40,
then these can be flushed out of the manifold 25 with a flow of ink
through the manifold ports 34, rather than becoming trapped in a
headspace above the ink flow.
[0209] Still referring to FIG. 10, the four ink supply channels 40
are arranged in pairs, with each pair being separated by a
longitudinal dividing wall 44. A relatively thicker longitudinal
central wall 46 separates the two pairs of ink channels 40. At a
base 48 of each ink supply channel 40 and at opposite sides of the
dividing wall 44 are defined a plurality of through-holes 50. The
through-holes 50 supply ink to two parallel rows of printhead chips
70, as will now be described with reference to FIGS. 11 to 13.
[0210] The through-holes 50 corresponding to one pair of ink supply
channels 40 extend downwardly from the bases 48 of the ink supply
channels towards a lower surface 52 of the manifold 25. Each
through-hole 50 has a first portion 54 which meets with a cavity
roof 55 of a longitudinal ink cavity 60 defined in the lower
surface 52 of the manifold 25. A longitudinal rib 58 extends
downwardly from the cavity roof 55 and divides the longitudinal ink
cavity 60 into a pair of longitudinal ink feed channels 56
positioned at opposite sides of the rib. The longitudinal rib 58
has an end surface 59 coplanar with the lower surface 52 of the
manifold.
[0211] The longitudinal ink cavity 60 has cavity sidewalls 62,
which extend downwardly from the cavity roof 55 to meet with the
lower surface 52 of the manifold 25. A second portion 64 of each
through-hole 50 extends beyond the cavity roof 55 to meet with the
lower surface 52. In this way, the second portions 64 of the
through-holes 50 form notches in the cavity sidewalls 62.
Similarly, and as best shown in FIG. 11, at least part of the first
portions 54 of the through-holes 50 form notches in opposite sides
of the dividing wall 44.
[0212] The notches defined by the second portions 64 of the
through-holes 50 provide a space for air bubbles to expand and rise
away from the printhead chips 70 during use. In the embodiment
shown, the through-holes 50 are circular in cross-section with the
first portion 54 and second portion 64 being generally
semi-circular. However, it will be appreciated that the
through-holes 50 may be of any suitable cross-sectional shape for
optimizing ink flow and bubble management.
[0213] As best shown in FIGS. 13 and 14, an Invar shim 66 is
adhesively bonded to the lower surface 52 of the manifold 25 and
the coplanar end surfaces 59 of the longitudinal ribs 58 so as to
bridge across each of the longitudinal ink feed channels 56. Thus,
the shim 66 seals across the second portions 64 of the
through-holes 50, which meet with the lower surface 52 of the
manifold 25.
[0214] In the embodiment shown, the shim 66 is a single-part shim
bonded to the lower surface 52 of the manifold 25 so as to bridge
across all four longitudinal ink feed channels 56 corresponding to
the four colors of ink. Rows of butting printhead chips 70 are
adhesively bonded to the shim 66 over a respective pair of ink feed
channels 56 to form the first row 14 and the second row 16 of
printhead chips.
[0215] The Invar shim 66, shown in isolation in FIG. 16, provides a
stable platform for each row of printhead chips 70 with negligible
thermal expansion during use. The Invar shim 66 is typically has an
adhesion-promoting surface film layer in order to optimized bonding
to the silicon printhead chips 70.
[0216] The shim 66 has a comparable thickness to the printhead
chips 70 (e.g. about 100 to 1000 microns in thickness) and the
surface film layer is typically from 50 nm to 5 microns in
thickness, depending on the deposition technique and whether a
monolayer or multilayer coating is employed. Effectively, the Invar
shim 66 enables construction of long printheads based on a
monolithic manifold to which a plurality of printhead chips can be
mounted.
[0217] Use of a singular shim 66 having a pair of longitudinal shim
sections 66A and 66B minimizes relative skew of the first row 14
and second row 16 of printhead chips 70 by ensuring parallelism
between the two shim sections 66A and 66B. Alignment of the shim 66
relative to the manifold 25 is facilitated using mechanical
alignment tabs 61 on the shim, which engage with alignment features
63 in the form of recesses defined in the lower surface (see FIG.
14). It will be appreciated that the shim 66 has a number of
alignment tabs 61 positioned for engagement with a corresponding
plurality of alignment features 63 in the manifold 63. A plurality
of alignment tabs 61 ensures alignment in both x- and y-axes.
[0218] A central longitudinal portion of the shim 66 defines voids
68 between a series of shim trusses 67 connecting the two main
longitudinal sections 66A and 66B. Accordingly, a region between
the first row 14 and second row 16 of printhead chips 70 is
relatively thermally isolated from the lower surface 52 of the
manifold 25, which acts a heat sink cooled by ink circulating
through the manifold. Thermal isolation of this central region of
the printhead 1 assists in minimizing cool spots between the first
row 14 and second row 16 and advantageously minimizes condensation
of ink onto the underside of the printhead during printing.
[0219] In use, each row of printhead chips 70 receives two inks
from a respective pair of ink supply channels 40. Ink is supplied
into the pair of longitudinal ink feed channels 56 via the
through-holes 50, and thence into the backsides the printhead chips
70 via a pair of longitudinal shim slots 69 defined in each
longitudinal shim section 66A and 66B. The longitudinal shim slots
69 extend along opposite sides of a longitudinal shim rib 72, which
is itself aligned with the longitudinal rib 58 of the manifold
25.
[0220] The longitudinal ink feed channels 56 provide an open ink
channel architecture, whereby a relatively large body of ink is in
close proximity to the backsides of the printhead chips 70. This
arrangement is suitable for printing at high print frequencies,
whilst ensuring that inkjet nozzles in the printhead chips do not
become starved of ink. Furthermore, the enlarged through-holes 50,
each having a second portion 64 meeting with the shim 66 and offset
from the printhead chips 70, provide a bubble-tolerant architecture
whereby the risk of trapped air bubbles blocking a flow of ink into
the printhead chips is minimized. Moreover, the first portions 54
and second portions 64 of the through-holes 50 facilitate venting
of trapped air bubbles into the ink supply channels from where any
air bubbles may be readily flushed from the printhead 1.
[0221] Ink is supplied from the shim slots 72 to corresponding ink
delivery slots defined in the backside of each printhead chip 70. A
typical Memjet.RTM. printhead chip 70, shown in FIG. 15, comprises
five color channels for potentially printing five inks. Five color
channels in a single printhead chip provides flexibility for
various different printing configurations and, hitherto,
Memjet.RTM. printhead chips 70 have been plumbed for printing
CMYK(IR), as described in U.S. Pat. No. 7,524,016; CMYKK as
described in U.S. Pat. No. 8,613,502, CCMMY as described in U.S.
Pat. No. 7,441,862, or monochrome (e.g. KKKKK) as described in US
2017/0313067, the contents of each of which are incorporated herein
by reference. In the printhead 1, the first row 14 contains
Memjet.RTM. printhead chips 70, which are typically plumbed for
printing two colors of ink and the second row 16 contains
Memjet.RTM. printhead chips, which are typically plumbed for
printing two different colors of ink for full-color (CMYK)
printing. Thus, the printhead 1 only makes use of four of the five
available color channels in the Memjet.RTM. printhead chip. As
shown in FIG. 15, two outer color channels 71A are used to print
one color of ink fed from a respective ink feed channel 56; two
opposite outer color channels 71B are used to print another color
of ink fed from another respective ink feed channel; and the
central color channel 71C contains a dummy row of non-ejecting
nozzles, which do not receive any ink from the manifold 25. As best
shown in FIG. 13, a central portion of the printhead chip 70
corresponding to the dummy color channel 71C is aligned with the
longitudinal rib 58 of the manifold 25 to provide additional
mechanical support for mounting the printhead chip. A backside ink
delivery slot corresponding to the dummy channel 71C in the
printhead chip 70 may be non-etched or only partially etched to
provide additional mechanical support. In some embodiments, partial
etching of backside channels may be useful for accommodating
adhesive squeeze-out during mounting of the printhead chips 70.
[0222] Notwithstanding the mechanical advantages of the central
dummy color channel 71C in the printhead chip 70, additional
advantages may be achieved in terms of temperature regulation.
Although the row(s) of nozzles corresponding to the dummy color
channel 71C do not receive any ink, they may still be electrically
connected to a printer controller in order to heat the printhead
chip, as required. Temperature regulation across all color channels
in a printhead chip is important for achieving consistent print
quality and a central dummy row of non-ejecting nozzles, each
having an active heater element, may be used achieve improved
temperature regulation across the printhead chip.
[0223] Turning to FIGS. 17 to 19, the electrical wiring
arrangements for the printhead 1 will now be described in more
detail. A pair of longitudinal PCBs 18 flank the first row 14 and
second row 16 of printhead chips 70 at opposite sides thereof, each
PCB being bonded to the lower surface 52 of the manifold 25. Each
PCB 18 comprises a rigid substrate (e.g. FR-4 substrate) for
mounting of various electronics components and has one edge butting
against a step 74 defined in the lower surface 52 of the manifold
25. Each PCB 18 extends laterally outwards beyond the sidewalls 41
of the manifold 25. The shield plate 20 is bonded to a lower
surface of each PCB 18 and has plate slots 21 aligned with the
first and second rows 14 and 16 of printhead chips 70 as well as a
central longitudinal portion covering a region between the first
and second rows. The protruding portions of each PCB 18 and the
shield plate 20 define opposite wings 75 of the printhead 1, while
a uniformly planar lower surface of the shield plate 20 is
configured for engagement with a perimeter capper (not shown)
surrounding both rows of printhead chips.
[0224] An edge of each PCB 18 proximal a respective row of
printhead chips 70 has a respective row of pinouts 77, each pinout
being connected to a respective bond pad 73 on one of the printhead
chips via a wirebond connection (not shown). An encapsulant 79
protects the wirebonds and extends between the proximal edge of
each PCB 18 and an edge of the printhead chips 70 containing the
bond pads 73. An opposite edge of the printhead chips 70 is sealed
with grout material 81.
[0225] The PCBs 18 generate heat and warm the shield plate 20
exposed to ink aerosol during printing. As foreshadowed above, a
central portion of the shield plate 20 is relatively thermally
isolated from the manifold 25 by virtue of the voids 68 defined in
the shim 66. Accordingly, condensation of ink onto a central
longitudinal region of the shield plate 20, between the first row
14 and second row 16 of printhead chips 70, is minimized.
[0226] As best seen in FIG. 17, a row of contact pads 80 extends
longitudinally along a distal edge portion of an upper surface of
each PCB 18. Each lead 22 has one end connected to a contact pad 80
and extends upwardly towards a respective sidewall of the main body
17. The leads 22 have an upper portion mounted to a respective
flange 29 of the cover plate 27 via a lead retainer 24 affixed
thereto, and a lower portion which flares laterally outwards
towards the contact pads 80. Each lead 22 also has a portion
defining the electrical contact 13 for connection to external power
and data connectors of a printer. In this way, each row of
printhead chips 70 receives power and data from the electricals
contacts 13 via respective leads 22 and a respective PCB 18
adjacent the row of printhead chips.
[0227] Turning to FIG. 20, there is shown a schematic sectional
side view of the printhead having additional sealant 92 for
improving wiping of the printhead chips 70 by a compliant wiper 90.
Each plate slot 21 of the shield plate 20 (only one plate slot
shown in FIG. 20) has an inner perimeter of epoxy sealant 92
disposed on exposed portions of the underlying support structure
(e.g. the shim 66 and PCB 18). The sealant 92 has a profiled upper
surface tapering generally downwards from an upper edge of the
shield plate 20 towards the support structure. The sealant 92
extends continuously around the recessed perimeter of the plate
slot 21, thereby covering any regions of the support structure that
are not covered by either the encapsulant 79 at one side of the
printhead chips 70 or the grout material 81 at an opposite side of
the printhead chips. By virtue of the perimeter sealant 92 the
compliant wiper 90 is able to seal more effectively against the
printhead surface (including uppers surfaces of the printhead chips
70, the shield plate 20, the encapsulant 79, the grout material 81
and the sealant 92 as shown in FIG. 20) by minimizing sharp or
stepwise height transitions across the printhead surface. Effective
sealing between the wiper 90 and the printhead surface is
particularly advantageous for wipers of the type combining suction
and wiping. With sharp height transitions across the printhead
surface, suction wiping becomes less effective since the compliant
wiper 90 cannot form an effective seal with the printhead surface.
Furthermore, the epoxy sealant 92 advantageously minimizes ingress
of ink into adhesive bonds between, for example, the shield plate
20 and the underlying support structure (e.g. PCB 18 or shim
66).
[0228] The printhead 1 described hereinabove therefore has a number
of features for addressing the challenges of pagewide printing,
especially full-color pagewide printing using relatively long
printheads.
[0229] It will, of course, be appreciated that the present
invention has been described by way of example only and that
modifications of detail may be made within the scope of the
invention, which is defined in the accompanying claims.
* * * * *